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At least 415 records · Page 23

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DOE OSTI2021

Intelligence-assisted predesign for the sustainable recycling of lithium-ion batteries and beyond

The unprecedented consumption of lithium-ion batteries (LIBs) is occurring to meet the needs of modern transportation electrification. Recycling-friendly designs intrinsically facilitate the long-term sustainable utilization of natural resources, reducing the detrimental impacts of spent LIBs on the environment, and improving the economic viability of recycling. For this, we propose the incorporation of an intelligence-assisted predesign strategy into the battery-management system and battery chemistry, including ameliorating the traceability of battery structure and operation status, promoting cost-effective material sorting and separation, and adopting sustainable battery materials. The purposeful predesign of intelligent “Reuse–Refurbish–Recover” (3R) LIBs could be realized in an economically and environmentally sustainable (EES) manner. We report the intelligence-assisted predesign strategy will promote multi-disciplinary cooperation in a systematic and synergetic way; in addition, it will empower governments to establish and implement a series of regulations and standards for addressing the environmental pollution issues from spent batteries, thus avoiding the ever-increasing consumption of natural resources.

25 ENERGY STORAGE↗

DOE OSTI2024

Recycled dark matter

Here, we outline a new production mechanism for dark matter that we dub “recycling”: dark sector particles are kinematically trapped in the false vacuum during a dark phase transition; the false pockets collapse into primordial black holes (PBHs), which ultimately evaporate before Big Bang Nucleosynthesis (BBN) to reproduce the dark sector particles. The requirement that all PBHs evaporate prior to BBN necessitates high scale phase transitions and hence high scale masses for the dark sector particles in the true vacuum. Our mechanism is therefore particularly suited for the production of ultra heavy dark matter (UHDM) with masses above ~10 12 GeV. The correct relic density of UHDM is obtained because of the exponential suppression of the false pocket number density. Recycled UHDM has several novel features: the dark sector today consists of multiple decoupled species that were once in thermal equilibrium and the PBH formation stage has extended mass functions whose shape can be controlled by IR operators coupling the dark and visible sectors.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2023

Extending the low-recycling, flat temperature profile regime in the lithium tokamak experiment-β (LTX-β) with ohmic and neutral beam heating

Abstract Recent experiments in the lithium tokamak experiment- β (LTX- β ) have extended the duration, performance, operating conditions, and diagnosis of the flat-temperature profile, low-recycling regime first observed in LTX. As expected, Li retains hydrogen and suppresses edge neutral cooling, allowing increased edge electron temperature, roughly equal to the core T e . Flat temperature profiles had been obtained transiently in LTX, as the plasma density decayed following the cessation of edge gas puffing. Careful control over the fueling in LTX- β has now been shown to sustain the flat T e profile and hot edge unique to the low-recycling regime for multiple confinement times in high performance discharges with decaying or steady density. With low density, the flat T e profile is also seen to extend into the scrape-off layer. Neutral beam heating is observed in target discharges with relatively flat electron temperature profiles ( T edge ∼ T core /2), though beam heating is stronger in discharges with higher fueling, higher density, and depressed edge T e . Beam heating produces additional peaking of the T e profile, without degradation of the energy confinement time. Neutral beam heating of target discharges with relatively flat electron temperature profiles similarly results in broad beam heated temperature profiles. Energy confinement in LTX- β generally compares favorably to ohmic and H-mode scalings, frequently exceeding them by factors of 2–4. New and improved diagnostics in LTX- β enable better characterization of this unique regime, including measurements of ion temperature and high field side Thomson scattering profiles. As an initial step toward characterizing turbulence with no T e gradient and roughly equal density and pressure gradient, core fluctuation spectra have been measured in peaked T e discharges using far-forward scattering and fluctuation reflectometry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Rerouting of the lignin biosynthetic pathway by inhibition of cytosolic shikimate recycling in transgenic hybrid aspen

Lignin is a phenolic polymer deposited in the plant cell wall and is mainly polymerized from three canonical monomers (monolignols), i.e., p-coumaryl, coniferyl, and sinapyl alcohols. After polymerization, these alcohols form different lignin substructures. In dicotyledons, monolignols are biosynthesized from phenylalanine, an aromatic amino acid. Shikimate acts at two positions in the route to the lignin building blocks. It is part of the shikimate pathway which provides the precursor for the biosynthesis of phenylalanine, and is involved in the transesterification of pcoumaroyl- CoA to p-coumaroyl shikimate, one of key steps in the biosynthesis of coniferyl and sinapyl alcohols. The shikimate residue in p-coumaroyl shikimate is released in later steps, and the resulting shikimate becomes available again for the biosynthesis of new p-coumaroyl shikimate molecules. In this study, we inhibited cytosolic shikimate recycling in transgenic hybrid aspen by accelerated phosphorylation of shikimate in the cytosol through expression of a bacterial shikimate kinase. Here, this expression elicited an increase in p-hydroxyphenyl units of lignin and, by contrast, a decrease in guaiacyl and syringyl units. Transgenic plants with high shikimate kinase activity produced a lignin content comparable to that in wild-type plants and had an increased processability via enzymatic saccharification. Although expression of many genes was altered in the transgenic plants, elevated shikimate kinase activity did not exert a significant effect on the expression of the majority of genes responsible for lignin biosynthesis. The present results indicate that cytosolic shikimate recycling is crucial to the monomeric composition of lignin rather than for lignin content.

shikimate pathway↗

DOE OSTI2020

Recycling of multilayer plastic packaging materials by solvent-targeted recovery and precipitation

Many plastic packaging materials manufactured today are composites made of distinct polymer layers (i.e., multilayer films). Billions of pounds of these multilayer films are produced annually, but manufacturing inefficiencies result in large, corresponding postindustrial waste streams. Although relatively clean (as opposed to municipal wastes) and of near-constant composition, no commercially practiced technologies exist to fully deconstruct postindustrial multilayer film wastes into pure, recyclable polymers. Here, we demonstrate a unique strategy we call solvent-targeted recovery and precipitation (STRAP) to deconstruct multilayer films into their constituent resins using a series of solvent washes that are guided by thermodynamic calculations of polymer solubility. We show that the STRAP process is able to separate three representative polymers (polyethylene, ethylene vinyl alcohol, and polyethylene terephthalate) from a commercially available multilayer film with nearly 100% material efficiency, affording recyclable resins that are cost-competitive with the corresponding virgin materials.

36 MATERIALS SCIENCE↗

DOE OSTI2026

A Reverse Logistics Tool For Ev Battery Recycling And Repurposing,

The demand for electric vehicles (EVs) in the United States is projected to rise significantly, with sales expected to reach approximately 4.1 million units by 2030. However, the U.S. remains heavily reliant on imports for the batteries and critical raw materials—such as lithium, cobalt, and nickel—that power these vehicles. As of 2024, around 70% of these imports originate from China. This dependency has become even more precarious following China’s imposition of export restrictions in April 2025, a retaliatory move against U.S. tariffs. These developments highlight the strategic vulnerabilities posed by China’s dominant position in the critical materials market. Compounding the issue, decades of intensive extraction have severely depleted global reserves of critical materials, widening the gap between supply and growing demand. This situation underscores the urgent need for the U.S. and other nations to diversify their sources of critical materials and enhance domestic capabilities to secure these resources—an essential step toward ensuring long-term energy security. At the end of their lifecycle—whether due to the battery’s degradation or the retirement of the vehicle—EV batteries are often improperly disposed of or sent to landfills. However, many of these batteries still retain usable capacity and can follow one of three alternative pathways: (a) Re-used: deployed in another vehicle with a shorter driving range, (b) Re-purposed: utilized act as a backup storage/power for data centers, solar panels, and e-scotters or (c) Recycled: broken down to recover the critical materials. To that end, the proposed tool (REBORN) is designed to optimize the reverse logistics network for battery repurposing and recycling. Its goal is to minimize associated costs while identifying optimal locations for battery collection and processing. Ultimately, REBORN ensures that each battery is used to its fullest potential.

Srinivas, SrikarV. [Idaho National Laboratory (INL↗

DOE OSTI2022

Third-Order Resonance Compensation at the FNAL Recycler Ring

The Recycler Ring (RR) at the Fermilab Accelerator Complex performs slip-stacking on 8 GeV protons, doubling the beam intensity delivered to the Main Injector (MI). At MI, the beam is accelerated to 120 GeV and delivered to the high energy neutrino experiments. Femilab’s Proton Improvement Plan II (PIP-II) will require the Recycler to store 50% more beam. Simulations have shown that the space charge tune shift at this new intensity will lead to the excitation of multiple resonance lines. Specifically, this study looks at normal sextupole lines 3 Q_{x}=76 and Q_{x}+2Q_{y}=74, plus skew sextupole lines 3 Q_{y}=73 and 2 Q_{x}+Q_{y}=75. Dedicated normal and skew sextupoles have been installed in order to compensate for these resonance lines. By measuring and calculating the Resonance Driving Terms (RDT), this study shows how each of the resonance lines can be compensated independently. Furthermore, this study shows and discusses initial investigations into compensating multiple lines simultaneously.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Simultaneous Compensation of Third-Order Resonances at the FNAL Recycler Ring

Third-order resonance lines will have a detrimental effect on the high-intensity operation of the Recycler Ring (RR), under the current Proton Improvement Plan (PIP-II) for the Fermilab Accelerator Complex. Increasing intensity will increase space charge effects, leading to the excitation of normal and skew sextupole lines. Dedicated normal and skew sextupoles have been installed in order to mitigate the effect of these resonance lines. By measuring the response matrix of the third-order Resonance Driving Terms (RDTs) to the currents of these dedicated elements, this study shows how several resonance lines can be compensated simultaneously. Resonance compensation is experimentally verified through loss maps and emittance growth measurements using the Ion Profile Monitor (IPM) system in the Recycler.

43 PARTICLE ACCELERATORS↗

DOE OSTI2025

Single-Bunch Instabilities at the Fermilab Recycler Ring

Understanding and characterizing collective instabilities is critical for high-intensity operation at the Fermilab Recycler Ring. This work presents an application of the the Nested Head-Tail (NHT) formalism for modeling single-bunch transverse instabilities, incorporating analytical solutions to the resistive wall impedances in the absence of space charge. Predicted growth rates and mode structures are benchmarked against PyHEADTAIL simulations and ongoing experimental measurements. The experimental program includes studies of bare-machine instabilities at different machine parameters. These results support the understanding of naturally-occurring instabilities in the Recycler and contribute to the development of predictive tools for beam stability in future high-intensity configurations.

Gonzalez-Ortiz, C. [Fermilab]↗

DOE OSTI2020

Fast growing high-yield wheat and canola for efficient nutrient recycling systems

Wheat and canola are two major rotation crops in the U.S. each offering advantageous traits for the agricultural value chain. Canola, a dicot rotation crop, generally offers high seed oil content. Wheat, a monocot rotation crop, offers more cellulose and other nutritious carbohydrates. As rotation crops, traits such as rapid growth rates, increased harvest yields, and high quality (digestibility, deconstructability) are desirable for food, biorefinery, and also nutrient recycling for crop rotation. Improvement of such traits has been the goal of numerous biotechnology efforts. However, alternative biotechnology techniques are typically constitutive and when applied to commercial crops have resulted in net negative consequences. For example, efforts to improve quality by lowering lignin biosynthesis have resulted in plants with poor structural integrity and diminished mass at maturity. With supports by SBIR programs from DOE and USDA, JBEI/LBNL and AFINGEN previously demonstrated engineered healthy switchgrass and alfalfa which grew with 20-30% more fermentable sugar release, 25% less lignin, faster growth, and more biomass yields than control plants. In this CRADA project supported by NASA STTR program, AFINGEN again collaborated with JBEI/LBNL and transferred the simple tissue-targeting technology from the demonstrated switchgrass and alfalfa to the two major rotation crops wheat and canola for efficient nutrient recycling systems.

09 BIOMASS FUELS↗

DOE OSTI2021

Recovery and Recycle of Irradiated Low-Enriched Uranium from the Production of 99 Mo

Technetium-99m ( 99m Tc), the daughter (decay product) of molybdenum-99 ( 99 Mo), is the most commonly used medical radioisotope in the world. 99 Mo is produced primarily from the fissioning of 235 U. A potential future producer, Eden Radioisotopes, is planning to irradiate low-enriched-uranium metal-foil targets for production of 99 Mo. Their plan is to recover, purify, and recycle the irradiated LEU in a new set of targets inside their facility. This study assesses processes to (1) purify and recycle uranium following 99 Mo recovery and (2) convert the uranium to metal for subsequent foil production and target fabrication. A UREX (uranium recovery by extraction) liquid–liquid extraction flowsheet that utilizes centrifugal contactors was developed using the Argonne model for universal solvent extraction (AMUSE) to recover and purify the uranium. The calculated flowsheet predicted high decontamination from Pu and most fission products and >99.99% recovery of uranium. Suggestions for conversion of the UREX U-product (uranyl nitrate in dilute nitric acid) to U metal were provided based on literature studies and earlier laboratory studies performed at Argonne National Laboratory.

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2022

Evaluation of the Impact of Additional Manganese from the Recycle Collection Tank (RCT) Glycolate Destruction Process on Glass Properties

The Defense Waste Processing Facility (DWPF) is planning to implement glycolic acid as a reductant within the waste processing flowsheet. An assessment of the glycolic acid flowsheet has revealed the potential for thermolytic production of hydrogen in the Concentration, Storage and Transfer Facilities (CSTF) from glycolate entrained in the DWPF recycle stream. To mitigate this potential scenario, a glycolate destruction process utilizing sodium permanganate (NaMnO 4 ) is being developed for use in the DWPF Recycle Collection Tank (RCT). The RCT is fed by the Slurry Mix Evaporator Condensate Tank (SMECT) and the Off-Gas Condensate Tank (OGCT). The SMECT could receive glycolate via a foamover from the Sludge Receipt and Adjustment Tank (SRAT) or the Slurry Mix Evaporator (SME), and the OGCT could receive glycolate via carryover of sludge particles in the purge from the melter during surge conditions. The use of NaMnO 4 additions in the RCT will result in additional manganese (Mn) in the waste stream and needs to be evaluated.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

CalTestBed - OnTo Technology - Characterization of Recycled Cathode and Anode Particles as a Function of Process Step (Final Report)

Onto Technology carries out advanced Li-ion battery recycling for industry and. has the only patented technology to produce manufacturing quality electrode materials from recycled batteries. The technology can resolve ongoing cost problems for the industry in life-cycle and conservation of critical materials. Under the Cal TestBed program, Onto Technology teamed with principal investigators at Lawrence Berkeley National Laboratory, who performed tests to evaluate the electrochemical performance of refurbished electrode materials. Other tests to determine structure and morphology of the refurbished materials carried out at LBNL included X-ray diffraction (XRD) and scanning electron microscopy (SEM).

36 MATERIALS SCIENCE↗

DOE OSTI2023

Fermilab Main Injector and Recycler Operations in the Megawatt Era

Significant upgrades to Fermilab’s accelerator complex have accompanied the development of LBNF (the Long Baseline Neutrino Facility) and DUNE (Deep Underground Neutrino Experiment). These improvements will facilitate 1-MW operation of the NuMI (Neutrinos at the Main Injector) beam for the first time this year through changes to the Recycler slip-stacking procedure and shortening of the Main Injector ramp time. The modifications to the Recycler slip-stacking and efforts to reduce the duration of the Main Injector ramp will be discussed. Additionally, details regarding further shortening of the ramp time and the subsequent impacts on future accelerator operations are presented.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2023

Natural Gas Combined Cycle (NGCC) Power Plants with Carbon Capture and Exhaust Gas Recycle (EGR)

The purpose of this study is to determine the cost and performance of natural gas combined cycle (NGCC) power plants using state-of-the-art gas turbines with post combustion carbon capture and recycle streams designed to increase the CO 2 concentration in the inlet to the capture system. Increasing the inlet CO 2 concentration by exhaust gas recycle (EGR) is expected to improve the efficiency of the capture system and reduce its costs. Primary results indicate that adding EGR to NGCC plants with CO 2 capture results in minimal improvement to the cost of electricity. The addition of 50 percent EGR in NGCC plants with CO 2 capture reduces the LCOE by 2 percent over the LCOE of the same design without EGR as reference. Including the EGR ductwork and cooler in a greenfield plant design could still be prudent since there is some cost advantage to EGR and it would allow more flexibility for taking advantage of future improvements in the technology.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Single-Bunch Instabilities at the Fermilab Recycler Ring

Gonzalez-Ortiz, Cristhian [Fermilab]↗

DOE OSTI2025

Economic Analysis of the NIF Optics Recycle Loop Systems Investment Options: SAE 560 - Economic Considerations for Systems Engineering at University of Southern California

The National Ignition Facility (NIF) relies on large-scale precision optics to deliver high-energy laser pulses for fusion and high-energy-density physics research; however, the NIF routinely operates above the damage threshold for those optics, decreasing their effectiveness with every experiment. A production line composed of several dozen highly specialized processing systems, collectively referred to as the ‘optics recycle loop’, was established to support refurbishment and re-use of these critical components to reduce reliance on high-cost and high-risk optic replacement strategies. This analysis aims to identify the most cost-effective investment options for improving recycle loop throughput by maximizing availability and production flexibility while minimizing the engineering and infrastructure efforts and cost.

42 ENGINEERING↗

DOE OSTI2025

Total Recycling of Copper Cable Scrap and Production of Carbon Using Fast Microwave Technology

The recycling of cable scrap, particularly from discarded electrical wiring, is gaining significant attention due to the rising demand for copper and the need for sustainable management of electronic waste. Traditionally, mechanical and thermal processings have been used to recover copper and plastic from cables. However, these approaches are often energy-intensive, time-consuming, and costly in terms of equipment and labor. In this study, we present a simple and effective method for recovering materials from cable scrap using a domestic microwave oven. Cable pieces (2–2.5 cm long) were exposed to 700 W of microwave irradiation under rotation for 30 s, enabling the rapid and efficient separation of high-quality copper metal from the core wire, and activated carbon from the carbonized plastic sheath. Microwaves facilitate this process through Ohmic heating, which induces electrical resistance in the metal, generating heat that mechanically loosens the metal and carbonized plastic components. The process demonstrates high efficiency, achieving an 80% reduction in energy consumption compared to conventional processings. This fast and energy-efficient method shows strong potential for scaling up to industrial recycling, offering a cost-effective and environmentally friendly way to recover high-quality materials for further use or repurposing.

Bourlinos, Athanasios B. (ORCID:0000000256165993)↗